Fibrous Insulating System with a Corrugated Thermal Break Core

ABSTRACT

A fibrous insulation blanket manufactured to be installed between standard, sub-standard, and super-standard framing within those wall, ceiling, and roof cavities between framing members in residential and commercial buildings. Said fibrous insulation blanket includes a structure of flexible corrugated/ribbed material serving as a structural thermal break comprised of a non-heat/cold transmitting material, which provides additional insulating characteristics beyond the capabilities of the fibrous insulating material for increased protection from heat loss and cold infiltration.

CROSS-REFERENCE TO RELATED APPLICATIONS

This is a new application.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not Applicable

INCORPORATION-BY-REFERENCE OF MATERIAL SUBMITTED ON A COMPACT DISC

Not Applicable

TECHNICAL FIELD AND INDUSTRIAL APPLICABILITY OF THE INVENTION

The present invention relates to a faced or un-faced pre-sized fibrous insulation blanket with a structural corrugated or ribbed thermal break core. Said structural corrugated thermal break contains air pockets and is located between the two major faces of the invention which is then located within the fibrous insulation blanket. This thermal break provides additional insulating characteristics beyond the basic insulating characteristics of any fibrous and non-fibrous material independently.

BACKGROUND OF THE INVENTION

A standard of the commercial and residential construction industry is the use of fiberglass, rock wool, or spun glass fibrous insulation, manufactured in roll or precut batt insulation packages and is placed into walls, roofs, and ceilings.

Fibrous insulation has been a worldwide staple in the construction industry for over 40 years. Previous to that time any insulation was used only in the colder climates and only occasionally in temperate climates. However, the history of this product shows a gradual progression to where insulation is now and for the past thirty plus years has been a requirement in most building codes in the United States in all climates as well as other developed countries.

Fibrous insulation, specifically, fiberglass batts and fiberglass loose fill, are used in more homes and commercial buildings than any other type of insulation.

Fiberglass insulation can cut the cost of heating and air conditioning by up to 40 percent vs. a non-insulated structure. The primary reason this insulation provides protection against heat loss and cold infiltration is that the spun glass fibers trap air. It is this trapped air that primarily provides this product with its insulating properties.

Another type of insulation for buildings is loose fill cellulose. This is a product made from small pieces of paper, processed wood, and other organic and inorganic material. Its insulating properties are also primarily derived from trapping air between and within the fibrous material.

This invention is a fibrous insulation blanket containing a thermal break core of predetermined thickness. This thermal break core contains, maintains, and protects pockets of air within its structure thereby providing additional and increased protection from heat loss and cold infiltration.

This invention is a fibrous insulation blanket containing a structural corrugated or ribbed thermal break core is pre-cut to fit wall, ceiling, and/or roof cavities.

This corrugated thermal break core adds rigidity and strength to the fibrous insulating blanket.

The corrugated or ribbed thermal break material would be made from a poor thermal conducting amalgam such as treated or untreated corrugated cardboard, paper, plastic, etc.

This fibrous insulating blanket with a corrugated or ribbed thermal break core is manufactured in standard or custom widths in order to be fitted into standard, sub-standard, or super-standard structural or non-structural cavities in ceilings, walls, rafters, dividing walls, partitions, and other such structures.

This new invention coincides with the current construction model in application, manufacture, storage, delivery, and marketing.

The new invention with the corrugated or ribbed thermal break core can be rolled, stored, and applied as simply as the current fiberglass/spun glass fibrous insulation batt and roll product.

This new invention with the corrugated insulating core is designed to be essentially the same thickness and same width as current fibrous spun glass/fiberglass products thereby fitting appropriately within the standard widths of ceiling joists, wall studs, roof rafters, interior and exterior walls, and other framing cavities.

Either or both major and/or minor surfaces of this product can be faced or un-faced with or without paper, foil, cardboard, plastic, air film, coatings, etc.

Facing on single or duel major and/or minor faces may also be applied and the product can still be installed in the same manner.

The fibrous insulation blanket with a corrugated or ribbed core feature is manufactured with the ribs of the core running widthwise from minor edge to minor edge, which assures the flexibility of the product when rolled and packaged and during installation.

The principal behind this innovation is to take advantage of an already fully accepted theory that air contained within a poor heat/cold transferring material and positioned as a thermal break, provides greater insulating properties than the same material without this innovation. This, even though, spun glass, cellulose, and other fibrous materials do not conduct heat or cold well and are adequate insulating materials on their own.

This corrugated or ribbed thermal break adds additional resistance to the conductivity of unwanted temperature variations from one major face and fibrous composite to the opposing major face and fibrous composite.

The stated claims and descriptions of this invention are not to be construed as limiting any options or modifications. It is to be understood that the invention is not to be limited to the enclosed embodiment, but on-the-contrary, is intended to cover any, various, many, modifications and equivalent arrangements included within the spirit and scope of the above claims and descriptions.

BRIEF DESCRIPTION OF THE DRAWINGS

Label 1 (FIGS. 1, 2,3) shows the thermal break core installed between an inner and outer portion of a fibrous insulation blanket (Labels 2 and 4.)

Labels 13 and 14 (FIGS. 1, 2,3) show the protected air pockets within the structure of the thermal break core.

Labels 17 (FIG. 2) shows the structure of the thermal break core.

TABLE 1 Label Key to FIGS. 1, 2, 3 Label # Description 1 Corrugated Thermal Break Core Structure 2 Interior Portion of the Fibrous Insulation Blanket with a Thermal Break Core 3 Vapor Barrier (if desired) installed on the Interior Side of the Fibrous Insulation Blanket 4 Exterior Portion of the Fibrous Insulation Blanket with a Thermal Break Core 5 Interior Minor Face of a Typical Wall Stud 6 End View of the Exterior Side of the Fibrous Insulation Blanket with a Thermal Break 8 Major Face of a Typical Wall Stud 9 Exterior Face of the Fibrous Insulation Blanket with a Thermal Break Core 10 Major Face of a Typical Wall Stud 12 Interior Minor Face of a Typical Wall Stud 13 Air Space within the Structure of the Thermal Break Core 14 Air Space within the Structure of the Thermal Break Core 15 2 × 4 Sill Plate for the Wall Structure 17 Corrugated Material Forming the Structure of the Thermal Break Core 18 Interior Drywall 19 Exterior Sheathing 20 Exterior Siding

4,866,905 September 1989 Bihy, et al 5,765,318 June 1998 Michelsen 5,848,509 December 1998 Knapp, et al 6,141,930 November 2000 Allwein, et al 6,357,504 March 2002 Patel, et al 6,383,594 May 2002 Weinstein, et al 6,415,573 July 2002 Moulder 6,468,615 October 2002 Weinstein, et al 6,484,463 November 2002 Fay 6,551,951 April 2003 Fay, et al 6,599,850 July 2003 Heifetz 6,551,677 November 2003 Weinstein, et al 6,670,011 December 2003 Weinstein, et al 7,857,923 December 2010 Suda, et al 

What is claimed:
 1. This invention is a pre-sized, fibrous insulation blanket with a structural corrugated or ribbed thermal break core. The fibrous insulation blanket may be faced (also providing excess face material on the interior major surface for the adhesion of this invention via staples, adhesive material, nails, tacks, etc.) or un-faced, treated or untreated. The corrugated thermal break may be made from corrugated cardboard, corrugated paper, plastic, sponge-like material, etc., and contains, maintains, and protects pockets of air within the corrugated structure and therefore provides increased insulative protection of the structure, residence, building area where used from heat loss and cold infiltration. The corrugated structural core may be faced with an air film on both, one, or neither major face. This fibrous insulation blanket with a structural corrugated or ribbed thermal break core is used for insulating standard, sub-standard, and super-standard widths and lengths of walls, ceilings, and/or roof cavities. This thermal break core provides additional insulating characteristics beyond the basic insulating characteristics of any fibrous material independently. This corrugated thermal break core is made of a material that is a poor thermal conducting amalgam such as treated or untreated corrugated cardboard, corrugated paper, plastic, sponge-like material, etc. and may be faced or un-faced with an air film. This corrugated core provides increased protection from heat loss and cold infiltration.
 2. The structure of the thermal break consists of two major faces, two minor edges, and the double surface face (two sides) of the currugated portion between the two major surfaces. Within the confines of the major surfaces, the minor edges, and the corrugated structure are air spaces which are confined, constructed, separated, and supported by the structure described above. This plethora of separating surfaces, which provide insulating properties on their own, combined with the air spaces, provides additional protection beyond that which would be provided by the same thickness of the fibrous insulation that the corrugated structure replaces.
 3. A pre-sized fibrous insulation blanket, with a structural corrugated/ribbed thermal break core of a predetermined thickness. This corrugated or ribbed thermal break of a predetermined thickness is manufactured to be centralized one half the distance between the two major faced or un-faced surfaces or any distance proportionally placed at any other appropriate distance between the two major surfaces of the insulating blanket and this corrugated or ribbed thermal break core of a predetermined thickness. The core extends from one edge or minor surface of the insulation blanket to the opposing edge or other minor surface of the insulation blanket and extends the entire length of the batt or roll.
 4. The thermal break structure according to claim 1, wherein: the corrugated structural core contains an amount greater or lesser than 98% air and an amount greater or lesser than 2% actual material. The air in the thermal break structure is located within and between the ribs of the corrugated material and between the two major surfaces of the corrugated structure.
 5. This faced or un-faced pre-sized fibrous insulation blanket with structural corrugated or ribbed thermal break core according to claim 2, wherein: is superior in insulating properties and superior in protection of the insulated area from heat loss and cold infiltration as compared to a similar fibrous insulation blanket containing the same overall thickness from one major surface to the opposing major surface of fibrous insulating material but without the corrugated thermal break core.
 6. This faced or un-faced pre-sized fibrous insulation blanket with structural corrugated or ribbed thermal break core according to claim 1, wherein: is flexible when being installed or rolled end-to-end with the width remaining the same and the length being shortened into a roll. The corrugated/ribbed structure is made from flexible, poor-temperature transmittal material, with the ribs installed and positioned in a side-to-side, minor surface to minor surface configuration, thus permitting the blanket to be rolled easily into a compact package.
 7. This faced or un-faced pre-sized fibrous insulation blanket with structural corrugated or ribbed thermal break core according to claim 1, wherein: this chemically treated or un-treated, faced or un-faced fibrous insulation blanket with a thermal break core is used for insulating standard, sub-standard, and super-standard widths and lengths of walls, ceilings, or roof cavities.
 8. The corrugated thermal break material according to claim 1, wherein: is made of a material that is a poor thermal conducting amalgam such as treated or untreated corrugated cardboard, corrugated paper, plastic, etc. which contains, maintains, and protects major air spacing within the structure of the corrugated core to provide increased insulating qualities, superior to that of just fibrous material.
 9. The pre-sized fibrous insulation blanket with a structural corrugated or ribbed thermal break core, according to claim 1, wherein: has standard widths of 14½″ and 22½″ and a standard (when naturally expanded and un-packaged) thickness of 3½″, 5½″, 7½″, 9¼″ or 11¼″ or any other standard or customized width or thickness.
 10. The pre-sized fibrous insulation blanket with a structural corrugated or ribbed thermal break core, according to claim 1, wherein: has a standard width of 14½″ and 22½″ and a custom width of any size.
 11. The pre-sized fibrous insulation blanket with a structural corrugated or ribbed thermal break core, according to claim 1, wherein: has a standard thickness of 3½″, 5½″, 7½″, 9¼″ or 11¼″ or any other standard or customized width or thickness.
 12. The pre-sized fibrous insulation blanket with a structural corrugated or ribbed thermal break core according to claim 1, wherein: is faced or un-faced, treated or untreated, with or without paper, metal foil, fire retardant, adhesive, air film or any other material or product.
 13. The pre-sized fibrous insulation blanket with a structural corrugated or ribbed thermal break core according to claim 1, wherein: is treated or un-treated on the interior facing or exterior facing surface with or without fire retardant material.
 14. The pre-sized fibrous insulation blanket with a structural corrugated or ribbed thermal break core according to claim 1, wherein: is made from treated or un-treated, faced or un-faced fire retardant fibrous material.
 15. The pre-sized fibrous insulation blanket with a structural corrugated or ribbed thermal break core according to claim 1, wherein: can be installed in parallel batts to fill wider than standard wall, ceiling, roof, or other cavities.
 16. The pre-sized fibrous insulation blanket with a structural corrugated or ribbed thermal break core according to claim 1, wherein: can be installed in several layers to provide additional insulating values with additional thermal break insulating cores in order to fill cavities deeper than standard cavities.
 17. The pre-sized fibrous insulation blanket with a structural corrugated or ribbed thermal break core according to claim 1, wherein: can be installed in layers where the depth of the cavities permits, and will provide layered corrugated thermal breaks.
 18. The pre-sized fibrous insulation blanket with a structural corrugated or ribbed thermal break core according to claim 1, wherein: when installed in layers, will provide additional protection from heat loss and cold infiltration beyond a single layer with one thermal break.
 19. The pre-sized fibrous insulation blanket with a structural corrugated or ribbed thermal break core according to claim 1, wherein: the fibrous insulation blanket may be manufactured with more than one corrugated or ribbed thermal break core structure. 